Terminal structure



Nov. 24, 1936. RHODES 2,061,981

TERMINAL STRUCTURE Filed Jan. 21, 1955 ATTORNEYS Patented Nov. 24, 1936 9 UNITED STATES PATENT OFFICE TERMINAL s'rnuo'rmm Howard E. Rhodes, Floral Park, N. Y., assignor to Aerovox Corporation, corporation of New York Brooklyn, N. Y., a

Application January 21, 1935, Serial No. 2,655

14 Claims.

My present invention is concerned with electric condensers, primarily with condensers of the 'electrolytic type, and has its preferred application in electric motor starting.

An object of the invention is to provide a simple, inexpensive and durable arrangement by which only aluminum metal parts are exposed at the interior of the casing for prevention of condenser, which affords facilities not only for connecting the condensers in circuit, but also for connecting up auxiliary equipment, distinct therefrom, such as the centrifugal switch in electric motor starters.

In the accompanying drawing, in which are shown one or more of various possible embodiments of the several features of the invention, v

Fig. 1 is a plan view with the cover partly broken away of a condenser, incorporating the invention,

Fig. 2 is an end elevation of the condenser, showing a plan of the panel board,

Fig. 3 is a view in transverse section, on an enlarged scale, taken on line 3-3 of Fig. 1,

Fig. 4 is a similar view taken on line 44 of Fig. 1,

Fig. 5 is a view similar to Fig. 1, of an alternative embodiment, and

Fig. 6 is a transverse sectional view on an enlarged scale, taken on line 6-6 of Fig. 5.

Referring now to the .drawing, there is illustratively shown an electrolytic condenser including a conventional condenser roll C made up of formed aluminum foil electrodes l0 and II, with intervening absorbent sheets l2, carrying electrolyte and with protruding terminal tabs l3 and I4 integral with the respective electrodes. The unit is preferably flattened and, as usual, mounted in a rectangular aluminum container IS, with the usual flat cover l6, crimped thereabout and shown partly broken away.

The panel board preferably comprises a molded .block or plate I! of bakelite, vulcanite or the like, having integrally molded therewith, end ledges l8 and I9 rising therefrom The respective ledges have rising therefrom binding posts 2 0 and 2|, preferably of steel or brass, said posts 55 eachhavlng a head 22 embedded in the panel unit and molded thereinto. A sheet metal connecter strip 23 preferably encircles said post, extends the length of the ledge and is clamped in place by a binding post nut 24 about post 20. The panel at each end has a bushing portion 25 at the lower face thereof, lodged in a corresponding aperture 26in the casing wall. The panel is mounted in place, preferably by means of aluminum studs 21 extending through the casing wall,

the panel, the ledge l8 and the connecter strip 23, 10

over which the end of said aluminum stud is headed as at 28. Preferably, the stud 21 has a head 29 engaging an aluminum washer 90 pressed against an iisulating washer 3! which encircles the bushing 5. through terminal tab l3, which is clamped against head 29 by upsetting at 33 over an aluminum washer 34. Thus, the aluminum studs 21 in the respective ledges l8 and I9 serve the dual function of affixing the terminal panel I! to the casing I5 20 and of establishing electrical connection between terminal tabs l3 and M of the contained condenser unit and the respective binding posts 20 and 2|.

It is preferred, as shown, to dispose the binding 5 posts 20 and 2| at the ends of one diagonal of the panel, and the aluminum studs 21 at the ends of the other diagonal of the panel, which affords a particularly neat and attractive arrangement.

By the arrangement described, the circuit from the condenser to the binding post is from the aluminum stud 21 through the connecter strip 23 to the steel or brass terminal binding post 20. Thus, the mechanical strength of steel or brass is availed of, for binding post connection, for which purpose, aluminum is not so practical, while aluminum and no other metal subject to corrosion, is exposed at the interior of the casing. The construction is mechanically secure and waterproof.

Bosses 36 and 31 are shown in Figs. 1, 2 and 4 with steel or brass binding posts 38 and 39 respectively, headed at 40 molded thereinto exactly as in the case of binding post 20. Binding posts 38 and 39 which are electrically apart from the condenser C, serve for circuit connec tion of the centrifugal starting switch (not shown) in electric motor applications or for other apparatus associated with the condenser.

By the arrangement shown, while the panel is quite small, a maximum distance is afforded between each exposed metal part and the casing,

and by the staggered or diagonal arrangement of parts, a maximum distance is afforded be- A tip 32 on the stud head 29 extends 15 t.veen consecutive binding post nuts, for a minimum area of panel.

It is, of course, understood that the construction set forth, lends itself for application to a 5 greater orlesser number of binding posts, and that in the case of a grounded condenser unit, with only a single terminal, the ledge l8 alone at one .end of the panel might be used for that purpose and the rest of the panel dispensed 10 with.

It is also understood that while, in general, motor starting condensers are disposed in rectangular cases, as shown, the device lends itself for application to cylindrical or other shapes of i5 condenser casings, in which case, the panel board would be molded with appropriate concavity for engagement therewith.

In the construction set forth, the assembly of the parts if particularly easy, theactive con- I denser roll unit may have its terminal tabs Hi and I4 fixed in the first instance, to the aluminum studs 21 before insertion into the casing. After Washers 3| and have been slipped over studs 21, these are passed throughthe apertures 25 2'6 as the condenser is introduced into the casing. The panel is then positioned over studs 21 and the ends 28 are upset, which completes the assembly.

In the embodiment of Figs. 5 and 6, the alu minum stud at the interior and the steel or brass stud binding post at the exterior are shown in direct'axial alignment, instead of being offset as in Figs. 1 to 4. The aluminum stud element 4| protrudes through the casing wall I5 and at 43 is headed over an aluminum washer 44 which clamps the terminal tab l3 against aluminum washer 45 pressed against insulating washer 46, which in turn engages the'inner face of the condenser casing I5.

Y Referring to Fig. 6, the brass or steel binding within the insulating block or panel 5| to bond said elements into a unitary rigid construction extending in part into the boss 52. The aluminum stud 4| thus protrudes from one face of the panel and the binding post 41 from the boss 52 at the opposite face thereof.

While the invention has its preferred application to electrolytic condensers of the dry type, particularly for motor starting, it is understood that the invention affords a water tight connectlon useful also in applications to wet electrolytic condensers.

It will thus be seen that there is herein described apparatus in which the several features of this invention are embodied,-and which appa- 90 ratus in its action attains the various objects of the invention and is well suited to meet the requirements of practical use.

As many changes could be made in the above construction, and many apparently widely different embodiments of this invention could be made without departing from the scope thereof, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and g 7 not in a limiting sense.

Having thus described my invention, what I claim as newand desire to secure by Letters Patent of the United States is:-

1. An electrolytic condenser including an active capacity unit, a container can therefor a molded insulating panel engaging said can and having a ledge unitary therewith protruding from the exposed face thereof, an aluminum terminal stud through said can and through said panel and ledge, serving to affix said panel to said can, 5 and for terminal connection of said condenser unit, and a metal terminal post molded in said ledge, free from the contents of said can, and means effecting an electrical connection from said aluminum stud to said terminal post. 10

2. An electrolytic condenser comprising a metal can, a capacity unit within said can, an insulating panel at the exterior of said can, means firmly positioning said panel in contact with the exterior of said can, aluminum studs through said 15 can, electrically connected to the contained condenser, terminal posts molded in said panel at the exterior of said can and means at the exterior of said can associated with said panel, electrically connecting the aluminum studs to the corresponding terminal posts.

3. An electrolytic motor condenser, comprising an aluminum can, an active condenser unit including aluminum foil within the can, a molded insulating panel contacting said can and having 25 integral ledges rising therefrom, aluminum studs extending through said panel and the ledges thereof into said can, and electricallyand mechanically bondedto the unit, said studs serving also to affix the panel to the can, terminal posts 80 molded in said ledges, and metal bridge pieces along said ledges electrically connecting the aluminum studs to the respective terminal posts.

4. An electrolytic condenser comprising an aluminum can, an active unit therein including aluminum foil, a molded insulating panel having a face contacting said can and having integral ledges rising therefrom, terminal studs through the can and through the panel at corresponding ledges thereof, said studs electrically engaging 40 the terminals of the unit at their inner ends, and headed over the exposed faces of the ledges for mechanical connection of the panel and electrical connection of the unit, said ledges having terminal posts molded therein, and conducting metal 45 strips-on said ledges, electrically connecting the aluminum studs to the respective terminal posts.

5. An electrolytic condenser comprising an active unit having aluminum electrodes, a container therefor, a terminal unit at the exterior of said so container, comprising a molded block having a threaded binding post therein, and protruding therefrom, a conducting plate resting on said block and extending therealong from said post, an aluminum stud extending through said con- 55 tainer, through said block and through said plate, said stud engaging an electrode of the contained condenser unit for terminal connection thereof and engaging said plate for electrical connection therefrom to thebinding post. .0

I 6. An electrolytic condenser comprising an active unit including aluminum electrodes with terminal tabs, a rectangular aluminum enclosure can therefor, an insulating molded panel engaging one side of said can and having unitary g5 ledges rising from opposite ends thereof. threaded binding posts molded in and rising from said ledges, conducting metal strips extending along said ledges and connected to said respective posts and aluminum studs extending through the en- 19 closure can and the panel at the respective ledges thereof, headed over said plates at their outer ends, and secured with respect to the condenser tabs at their inner ends.

7. An electrolytic motor starting condenser, u

comprising an active unit with aluminum foil electrodes, an aluminum containing can therefor, a molded insulating panel block against one side of said can and having unitary ledges and unitary bosses rising therefrom, each of said ledges and bosses having a binding post molded therein, said ledges, each having a metal connector strip extending therealong, connected to the corresponding binding post, headed aluminum studs extending through the can, and through the respective ledges and the corresponding connector strips and headed thereover, to serve for electrical connection of the contained unit, and for mechanically afllxing said panel in place, the binding posts in said bosses serving for electrical connection of apparatus associated with but distinct from said condenser.

8. An electrolytic condenser including an active unit, an enclosure therefor, an insulating terminal-carrying block attached to the exterior of said enclosure, said block having an aluminum terminal stud associated therewith and extending through the wall of said enclosure, for terminal connection to the active unit, said block having a binding post exposed therefrom and electrical] connected to said aluminum stud.

9. In an electrolytic condenser, the combination of an active unit, a metal casing therefor, a molded insulating block, an aluminum stud protruding from one face of said block, a binding post protruding from the other face of said block, said stud and post electrically connected at the exterior of said molded block.

10. As an article of manufacture, a binding post panel for an electrical condenser, said panel comprising a molded block having a conductor strip thereagainst, a binding post molded in said block and contacting said strip, said block having a bore therethrough and through said strip adapted to accommodate an aluminum stud, to serve for afllxing said block to an electrolytic condenser casing and for electrical connection from a terminal of a condenser to the binding post.

-11. As an article of manufacture, a binding post panel for an electrical condenser, comprising a molded insulating plate having upstanding ledges at its ends and upstanding bosses between said ledges, binding posts molded in said ledges and in said bosses and protruding therefrom, conductor strips extending from the corresponding posts along said ledges, said panel with its ledges being bored in direction parallel to said posts, to accommodate aluminum studs to serve for mounting the panel on a condenser casing, and for establishing electrical connection from the contained unit, to the binding posts on said ledges.

12. In an electrolytic condenser, the combination of an active unit, a metal casing therefor, a molded insulating block, an aluminum stud protruding from one face of said block, a binding post protruding from the other face of said block, said stud and post elements in mechanical and electrical contact. at their engaging ends, said insulated block molded about the contacting portions of said stud and said post.

13. In an electrolytic condenser, the combination of an aluminum casing, an active unit therein, having an aluminum electrode with a terminal tab, an insulating block against said casing, said block having a composite binding post structure molded therein, and including an aluminum stud through the lower face thereof, extending into the casing for electrical and mechanical coaction with the terminal tab and a binding post protruding from the exposed face 'of said block.

14. As an article of manufacture, a terminal block for an electrolytic condenser, said block of molded insulating material, a composite binding elements being headed, one with a cup head for accommodating and embracing the other, said heads maintained in secure electrical contact within themolded block. 1

HOWARD E. RHODES. 

